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Opportunistic preventive maintenance scheduling for serial-parallel multistage manufacturing systems with multiple streams of deterioration

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  • Lu, Biao
  • Zhou, Xiaojun

Abstract

This paper proposes a novel opportunistic preventive maintenance (PM) scheduling methodology for the serial-parallel multistage manufacturing systems (SP-MMSs), where PM is performed to improve both the reliability and product quality. A SP-MMS has two essential characteristics: (i) the products can go through different process routes; (ii) the deterioration of a machine will not only affect the key product characteristics (KPCs) formed at the current stage but also propagate to downstream stages and then affect the KPCs formed there. Consequently, the propagation of machine deterioration along different routes will generate multiple streams of deterioration. This phenomenon is mathematically modeled to evaluate the quality of final products. The PM scheduling is based on the modeling of total maintenance cost including minimal repair cost, quality loss and PM-related costs. Firstly, a tentative PM schedule is made for each individual machine by minimizing the corresponding total maintenance cost. Secondly, the tentative PM schedules of all machines are further adjusted to obtain the optimal PM schedule for the system by jointly considering the economic dependence and control of final product quality. A case study shows that the methodology can ensure reasonably high reliability and final product quality for the system with a low total maintenance cost.

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  • Lu, Biao & Zhou, Xiaojun, 2017. "Opportunistic preventive maintenance scheduling for serial-parallel multistage manufacturing systems with multiple streams of deterioration," Reliability Engineering and System Safety, Elsevier, vol. 168(C), pages 116-127.
    • Handle: RePEc:eee:reensy:v:168:y:2017:i:c:p:116-127
    DOI: 10.1016/j.ress.2017.05.017
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    Cited by:

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    5. Aseem K. Mishra & Divya Shrivastava & Prem Vrat, 2020. "An opportunistic group maintenance model for the multi-unit series system employing Jaya algorithm," OPSEARCH, Springer;Operational Research Society of India, vol. 57(2), pages 603-628, June.
    6. Liu, Gehui & Chen, Shaokuan & Jin, Hua & Liu, Shuang, 2021. "Optimum opportunistic maintenance schedule incorporating delay time theory with imperfect maintenance," Reliability Engineering and System Safety, Elsevier, vol. 213(C).
    7. Jiang, Junwei & An, Youjun & Dong, Yuanfa & Hu, Jiawen & Li, Yinghe & Zhao, Ziye, 2023. "Integrated optimization of non-permutation flow shop scheduling and maintenance planning with variable processing speed," Reliability Engineering and System Safety, Elsevier, vol. 234(C).
    8. Wang, Lin & Lu, Zhiqiang & Ren, Yifei, 2020. "Joint production control and maintenance policy for a serial system with quality deterioration and stochastic demand," Reliability Engineering and System Safety, Elsevier, vol. 199(C).
    9. Pablo Viveros & Rodrigo Mena & Enrico Zio & Leonardo Miqueles & Fredy Kristjanpoller, 2023. "Integrated planning framework for preventive maintenance grouping: A case study for a conveyor system in the Chilean mining industry," Journal of Risk and Reliability, , vol. 237(5), pages 1011-1028, October.
    10. Rokhforoz, Pegah & Fink, Olga, 2022. "Maintenance scheduling of manufacturing systems based on optimal price of the network," Reliability Engineering and System Safety, Elsevier, vol. 217(C).
    11. Wang, Wenzhuo & He, Yihai & Liao, Ruoyu & Cai, Yuqi & Zheng, Xin & Zhao, Yu, 2022. "Mission reliability driven functional healthy state modeling approach considering production rhythm and workpiece quality for manufacturing systems," Reliability Engineering and System Safety, Elsevier, vol. 226(C).
    12. Zhang, Chengjie & Qi, Faqun & Zhang, Ning & Li, Yong & Huang, Hongzhong, 2022. "Maintenance policy optimization for multi-component systems considering dynamic importance of components," Reliability Engineering and System Safety, Elsevier, vol. 226(C).
    13. Azizi, Fariba & Salari, Nooshin, 2023. "A novel condition-based maintenance framework for parallel manufacturing systems based on bivariate birth/birth–death processes," Reliability Engineering and System Safety, Elsevier, vol. 229(C).
    14. Zhou, Xiaojun & Ning, Xiaohan, 2021. "Maintenance gravity window based opportunistic maintenance scheduling for multi-unit serial systems with stochastic production waits," Reliability Engineering and System Safety, Elsevier, vol. 215(C).
    15. Zhou, Xiaojun & Yu, Mengqi, 2020. "Semi-dynamic maintenance scheduling for multi-station series systems in multi-specification and small-batch production," Reliability Engineering and System Safety, Elsevier, vol. 195(C).
    16. Zhang, Tian & Homri, Lazhar & Dantan, Jean-Yves & Siadat, Ali, 2023. "Models for reliability assessment of reconfigurable manufacturing system regarding configuration orders," Reliability Engineering and System Safety, Elsevier, vol. 231(C).
    17. Vu, Hai Canh & Do, Phuc & Fouladirad, Mitra & Grall, Antoine, 2020. "Dynamic opportunistic maintenance planning for multi-component redundant systems with various types of opportunities," Reliability Engineering and System Safety, Elsevier, vol. 198(C).
    18. Lu, Biao & Chen, Zhen & Zhao, Xufeng, 2021. "Data-driven dynamic predictive maintenance for a manufacturing system with quality deterioration and online sensors," Reliability Engineering and System Safety, Elsevier, vol. 212(C).
    19. Wu, Shaomin & Do, Phuc, 2017. "Editorial," Reliability Engineering and System Safety, Elsevier, vol. 168(C), pages 1-3.
    20. Shi, Haohao & Zhang, Ji & Zio, Enrico & Zhao, Xufeng, 2023. "Opportunistic maintenance policies for multi-machine production systems with quality and availability improvement," Reliability Engineering and System Safety, Elsevier, vol. 234(C).
    21. de Jonge, Bram & Scarf, Philip A., 2020. "A review on maintenance optimization," European Journal of Operational Research, Elsevier, vol. 285(3), pages 805-824.
    22. Hongming Zhou & Sufen Wang & Faqun Qi & Shun Gao, 2022. "Maintenance modeling and operation parameters optimization for complex production line under reliability constraints," Annals of Operations Research, Springer, vol. 311(1), pages 507-523, April.
    23. Feng, Hanxin & Xi, Lifeng & Xiao, Lei & Xia, Tangbin & Pan, Ershun, 2018. "Imperfect preventive maintenance optimization for flexible flowshop manufacturing cells considering sequence-dependent group scheduling," Reliability Engineering and System Safety, Elsevier, vol. 176(C), pages 218-229.
    24. Cheng, Guoqing & Li, Ling, 2020. "Joint optimization of production, quality control and maintenance for serial-parallel multistage production systems," Reliability Engineering and System Safety, Elsevier, vol. 204(C).

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